Rapidly dissolvable polymer films and articles made therefrom

ABSTRACT

A film-forming composition for use in preparing water-soluble films that are rapidly dissolving under cold water conditions, the composition comprising a water soluble polymer material such as polyvinyl alcohol and a principal solvent, typically diol(s) or derivative of a diol. Films made from the film-forming compositions may be used to encapsulate a variety of compositions for subsequent release into an aqueous medium. Encapsulated compositions can include various laundry detergents and additives, fabric care compositions such as fabric softening compositions and dishwashing detergents among others. When used to encapsulate compositions, the solvent system used in the film-forming composition will have at least one common solvent material as the solvent system used in the encapsulated composition to improve film dissolution and to prevent problems associated with solvent migration.

This application claims the benefit of Provisional Application No.60/265,221, filed Jan. 31, 2001.

FIELD OF THE INVENTION

The present invention relates to the development and use ofwater-soluble polymer materials and films and articles made therefromthat are readily dissolvable in cold water. The present invention iseven more particularly related to the use of such polymer materials informing water-soluble articles that contain a variety of consumerproduct compositions including but not limited to laundry and fabriccare compositions, and other compositions that are commonly used and/ordiluted in cold water.

BACKGROUND OF THE INVENTION

Water-soluble films and their use in forming water-soluble articles arewell known in the art.

U.S. Pat. No. 3,186,869, issued Jan. 29, 1962, COATED FILM FOR LAUNDRYPACKAGE, and U.S. Pat. No. 3,322,674, issued Jun. 26, 1964, LAUNDRYPACKAGE, disclose water-soluble films and laundry articles madetherefrom which contain a detergent and chorine based bleaching agent.The water-soluble films in these references are internally coated with awax or other material to prevent the contents of the package frominteracting with the film material and degrading its solubilitycharacteristics.

U.S. Pat. No. 3,413,229, issued Nov. 26, 1968, POLYVINYL ALCOHOLCOMPOSITIONS, teaches the use of a plasticizer in PVA compositions thatare used to form laundry packets for detergents and/or bleaches in orderto maintain the solubility characteristics of the film after storage.

U.S. Pat. No. 3,892,905, issued Jul. 1, 1975, COLD WATER SOLUBLE PLASTICFILM, discloses a cold water soluble film that comprises a combinationof polymers having different molecular weights. The lowest molecularweight polymer suggested is about 21,000.

U.S. Pat. No. 4,119,604, issued Oct. 10, 1978, POLYVINYL ALCOHOLCOMPOSITIONS FOR USE IN THE PREPARATION OF WATER-SOLUBLE FILMS,discloses a cold water soluble film that comprises a low molecularweight PVA and a medium molecular weight PVA. The “low” and “medium”molecular weights are not identified but are merely described in termsof the viscosity of a solution containing the polymer.

U.S. Pat. No. 4,481,326, issued Nov. 6, 1984, WATER-SOLUBLE FILMS OFPOLYVINYL ALCOHOL AND POLYVINYL PYRROLIDONE, discloses a cold watersoluble film for packaging various products. The film compriseshydrolyzed polyvinylacetate alcohol and polyvinyl pyrrolidone. Specificdata concerning the dissolution rate of the film in cold water is notdisclosed.

U.S. Pat. No. 4,544,693, issued Oct. 1, 1985, WATER-SOLUBLE FILM,discloses a water-soluble film that reportedly dissolves in water ascold as 5° C. The film is composed of polyvinyl alcohol, polyvinylpyrrolidone, ethoxylated alkyphenol, and polyhydric alcohol. Nodissolution data concerning the claimed film is provided.

U.S. Pat. No. 4,692,494, issued Sep. 8, 1987, WATER-SOLUBLE FILMS OFPOLYVINYL ALCOHOL AND POLYACRYLIC ACID AND PACKAGES COMPRISING SAME,discloses a cold water soluble film made of a blend of PVA andpolyacrylic acid.

U.S. Pat. No. 4,765,916, issued Aug. 23, 1988, POLYMER FILM COMPOSITIONFOR RINSE RELEASE OF WASH ADDITIVES, discloses water-soluble laminatefilm that comprises at least one methylcellulose layer of hydroxybutylmethylcellulose (HBMC) blended with hydroxypropyl methylcellulose (HPMC)and at least one layer of polyvinyl alcohol incorporating across-linking agent. The solubility of the laminate is intended to be pHrather than temperature dependent.

U.S. Pat. No. 4,801,636, issued Jan. 31, 1989, RINSE SOLUBLE POLYMERFILM COMPOSITION FOR WASH ADDITIVES discloses a water-soluble film thatis made from a blend of polyvinyl alcohol and alkyl cellulose and has ametalloid oxide component to inhibit the dissolution of the film in analkaline wash but allow dissolution in the less alkaline rinse. U.S.Pat. No. 4,972,017, issued Nov. 20, 1990, is a divisional of U.S. Pat.No. 4,801,636 that is directed to an article made from the film claimedin the '636 patent.

U.S. Pat. No. 5,272,191, issued Dec. 21, 1993, COLD WATER SOLUBLE FILMSAND FILM-FORMING COMPOSITIONS discloses water-soluble film made fromknown water-soluble film-forming polymers, and a second component thatis a water insoluble cellulose material. The cellulose is renderedinsoluble preferably through internal or external cross linkingreactions.

SUMMARY OF THE INVENTION

The present invention provides a film-forming composition for forming acold water soluble film, the composition comprising:

from about 50% to about 99.9% of a water-soluble polymer material and

from about 0.1% to about 50% of a principal solvent,

wherein a film formed from the film-forming composition will dissolve ina beaker of water at a temperature below about 68° F. with agitation, inless than about 5, preferably less than about 4, still more preferablyless than about 3 and even more preferably less than about 2 minutes.

The present invention further provides for a water-soluble film formedfrom the film-forming composition as well as an article wherein acomposition to be dispensed into an aqueous medium is enclosed orencapsulated in the cold water soluble film.

DETAILED DESCRIPTION OF THE INVENTION

All percentages, ratios and proportions herein are by weight, unlessotherwise specified. All temperatures are in degrees Celsius (°C.)unless otherwise specified. All documents cited are incorporated hereinby reference in their entireties. Citation of any reference is not anadmission regarding any determination as to its availability as priorart to the claimed invention.

As used herein, “comprising” means that other steps and otheringredients which do not affect the end of result can be added. Thisterm encompasses the terms “consisting of” and “consisting essentiallyof”.

As used herein, “cold water conditions” is intended to refer to anenvironment where there is sufficient water to dissolve the film, i.e.the concentration of film polymer does not exceed its solubility limitin cold water, and where the temperature of the water is less than about68° F. and more preferably is less than about 50° F. It is anticipatedthat the improvements in dissolution achieved with the films andarticles of the present invention will likely be seen under warm and hotwater conditions as well.

As used herein, “rapidly dissolving” is intended to refer to thedisintegration and subsequent dissolution of the polymer film in lessthan about 5 minutes, preferably less than about 3 minutes and morepreferably less than about 2 minutes after the film or an article madetherefrom is placed in cold water conditions.

Film-Forming Compositions

The film-forming compositions of the present invention comprisewater-soluble film-forming polymer material and principal solvent.Optionally, the film-forming compositions may contain a variety ofadjunct ingredients that are well known to those in the film-formingart. Each of these components can be varied according to the levelsdesired in a given cold water soluble film.

A. Water-Soluble Film-Forming Polymers

Any water-soluble, film-forming polymer, or mixtures of polymers, may beused in the film-forming compositions of the present invention. Thepolymers usually are vinyl polymers, including homopolymers andcopolymers, having functionality rendering the polymers water-soluble,such as hydroxyl and carboxyl groups. Typical water-soluble polymersinclude at least one of polyvinyl alcohol, partially hydrolyzedpolyvinyl acetate, polyvinyl pyrrolidone, alkyl celluloses such asmethylcellulose, ethylcellulose, propylcellulose and derivativesthereof, such as the ethers and esters of alkyl celluloses, and acrylicpolymers such as water-soluble polyacrylates, polyacrylamides, andacrylic maleic anhydride copolymers. Suitable water-soluble polymersfurther include copolymers of hydrolyzed vinyl alcohol and anonhydrolyzable anionic comonomer, such as described in U.S. Pat. No.4,747,966 to Yang et al, cited above.

It will be evident that a wide variety of film-forming water-solublepolymer materials, including synthetic and natural polymers, andmixtures thereof, as described in standard textbooks on the subject andin the patent literature may be used to advantage. For example, inaddition to the U.S. patents cited above, Japanese unexamined patentapplications JP 01317506A published Dec. 22, 1989, and JP 60061504Apublished Apr. 9, 1985, describe water-soluble films of polyvinylalcohol, polyvinyl pyrrolidone, methylcellulose, cellulose acetate,polyethylene oxide, gelatin, partially saponified polyvinyl alcohol,CMC, dextrin, starch, hydroxyethyl cellulose, agar, pectin, and othersfor the packaging of process chemicals such as sodium sulfate and solidagricultural chemicals. Similarly, British Patent 2,191,379 granted Dec.16, 1987, describes the packaging of animal feed supplements in aplastic film of polyvinyl alcohol, polyvinyl acetate, ethylene/vinylacetate copolymer or an alkylcellulose ester. The disclosures of all ofthe above cited patents and patent applications are incorporated hereinby reference.

Particularly preferred film-forming polymers are polyvinyl alcohol,vinyl alcohol/vinyl acetate copolymers, polyvinyl pyrrolidone, gelatin,and mixtures of any of the foregoing. Polymer films comprising polyvinylalcohol can be prepared that are particularly rapidly dissolvable atcolder temperatures i.e. less than about 50° F. or less than about 40°F. Further, polyvinyl alcohols having varying average molecular weights(i.e. mean weights of the molar masses) such as from about 6,000 toabout 78,000 or higher may be used. Likewise, polyvinyl alcohol havingvarying degrees of hydrolysis may also be used to advantage. Preferably,such polymers are less than about 90%, more preferably less than about85%, and still more preferably less than about 80% hydrolyzed, but willbe more than about 60% and more preferably at least about 70%hydrolyzed. Blends of water-soluble polymers having different degrees ofhydrolysis may also be used to advantage. Other preferred film-formingpolymers include polyethylene oxide, polyvinyl pyrrolidone,hydroxypropyl methylcellulose and hydroxyethylcellulose.

Blends of water-soluble film-forming polymers may also be used toadvantage. Blends offer additional advantages in that rapidly dissolvingfilms can be produced with good mechanical properties for subsequenthandling and converting into manufactured articles. For instance, ablend containing at least two types of water-soluble polymers that havedisparate molecular weights, can be used to prepare film that is rapidlydissolving under cold water conditions. Preferably, such blends containat least one type of polymer that has a molecular weight greater thanabout 50,000, preferably greater than about 60,000 and even morepreferably greater than about 70,000, and a second polymer or mixture ofpolymers having an average molecular weight of less than about 30,000,more preferably less than about 15,000, and even more preferably lessthan about 10,000.

More specifically, a blend of at least one polyvinyl alcohol having amolecular weight of about 78,000 and higher and a second polyvinylalcohol about 6,000 or lower has been found to produce a rapidlydissolving film under cold water conditions. A low percentage of thehigher molecular weight polyvinyl alcohol, namely, less than about 50%preferably less than about 40%, and more preferably less than about 30%,will produces a film with adequate strength for converting into sachetsor coatings. A higher percentage of higher molecular weight polyvinylalcohol, namely, greater than about 50%, preferably greater than about60% and more preferably greater than about 70%, will provide theimproved strength and elasticity that is desired for vacuum formingoperations, but it should be noted that such higher percentages of highMW polymers are typically accompanied by increasingly higher dissolutiontimes. Blends of high and low molecular weight polymers at ratios of80/20, 60/40, and 50/50 mixtures of low to high molecular weightpolyvinyl alcohol can be evaluated for specific applications.

By way of example, a rapidly dissolving film can be prepared from ablend of polyvinyl alcohol that comprises from about 60% to about 95% ofpolyvinyl alcohol of an average molecular weight from about 3,000 toabout 30,000 and from about 5% to about 40% of polyvinyl alcohol of anaverage molecular weight from about 30,000 to about 200,000. The degreeof hydrolysis in the polyvinyl alcohol blend is preferably less thanabout 90 mol %, more preferably less than about 85% mol %, and stillmore preferably less than about 80 mol %. The film formed from thiscomposition can dissolve in a beaker of water at a temperature belowabout 68° F. in less than about 5 minutes with agitation.

In addition, blends of different types of polymer materials can also beformulated and prepared to produce the films of the present invention.For instance, ratios of 80/20, 60/40 and 50/50 with mixes of polyvinylalcohol and polyvinyl pyrrolidone, polyvinyl alcohol and polyethyleneoxide, polyvinyl alcohol and hydroxyethyl cellulose, polyvinylpyrrolidone and hydroxyethyl cellulose, polyvinyl pyrrolidone andpolyethylene oxide, and polyethylene oxide and hydroxyethyl cellulose,hydroxypropyl methylcellulose and polyvinyl alcohol, can be used toadvantage.

B. Principal Solvent

The film-forming compositions of the present invention comprise lessthan about 50%, preferably from about 5% to about 35%, more preferablyfrom about 8% to about 25%, and even more preferably from about 10% toabout 20%, of the principal solvent, by weight of the composition. Saidprincipal solvent is selected to minimize the time required for thewater-soluble film to disintegrate and dissolve under cold waterconditions. Dissolution data on films with and without a principalsolvent is presented below following the section entitled “SolubilityTest Method.”

The suitability of any principal solvent for the formulation of thefilm-forming composition herein is surprisingly selective consideringsolubility, film mechanical properties, and compatibility with thecomposition to be encapsulated by the film. Suitable solvents can beselected based upon the octanol/water partition coefficient (P) of thesolvent itself, and other solvent-polymer interactions. The principalsolvent may also consist of a mixture of these materials, which mayresult in an improvement in both film solubility and mechanicalproperties.

The octanol/water partition coefficient of a principal solvent is theratio between its equilibrium concentration in octanol and in water. Thepartition coefficients of the principal solvent ingredients of thisinvention are conveniently given in the form of their logarithm to thebase 10, ClogP.

The logP of many ingredients has been reported; for example, thePomona92 database, available from Daylight Chemical Information Systems,Inc. (Daylight CIS), Irvine, Calif., contains many, along with citationsto the original literature. However, the logP values are mostconveniently calculated by the “CLOGP” program, also available fromDaylight CIS. This program also lists experimental logP values when theyare available in the Pomona92 database. The “calculated logP” (ClogP) isdetermined by the fragment approach of Hansch and Leo (cf., A. Leo, inComprehensive Medicinal Chemistry, Vol. 4, C. Hansch, P. G. Sammens, J.B. Taylor and C. A. Ramsden, Eds., p. 295, Pergamon Press, 1990,incorporated herein by reference). The fragment approach is based on thechemical structure of each ingredient, and takes into account thenumbers and types of atoms, the atom connectivity, and chemical bonding.The ClogP values, which are the most reliable and widely used estimatesfor this physicochemical property, are preferably used instead of theexperimental logP values in the selection of the principal solventingredients which are useful in the present invention. Other methodsthat can be used to compute ClogP include, e.g., Crippen's fragmentationmethod as disclosed in J. Chem. Inf. Comput. Sci., 27, 21 (1987);Viswanadhan's fragmentation method as disclose in J. Chem. Inf. Comput.Sci., 29, 163 (1989); and Broto's method as disclosed in Eur. J. Med.Chem.—Chim. Theor., 19, 71 (1984).

The principal solvents herein are selected from those having a ClogP offrom about −2 to about 2.6, preferably from about −1 to about 1, morepreferably from about 0.15 to about 0.64, and even more preferably fromabout 0.40 to about 0.60, and said principal solvent preferably beingasymmetric. Solvents that have a low molecular weight and arebiodegradable are also desirable for some purposes. The more asymmetricsolvents appear to be very desirable, although highly symmetricalsolvents, having a center of symmetry such as 1,4-cyclohexanedimethanol,are also preferred.

Examples of preferred principal solvents include alcohols, and inparticular polyols such as diols. Specific non-limiting examples ofpreferred principal solvents include 1,4-butanediol, 1,3 butanediol and1,2-hexanediol, 2,2,4-trimethylpentanediol, ethoxylates of2,2,4-trimethylpentanediol, 2-ethyl 1,3 hexanediol, and 1,4cyclohexanedimethanol, and 1,2 cyclohexanedimethanol. For moleculesexhibiting isomerism, both the trans and cis forms can function asprincipal solvents. An extensive description of materials suitable foruse as principal solvents and as “simple” solvents are disclosed in U.S.Pat. No. 6,323,172, issued Nov. 27, 2001 to Trinh, et al., which isincorporated herein by reference.

In selecting the principal solvent for incorporation into awater-soluble film, for example a polyvinyl alcohol film, it isimportant to consider the composition of the material to be encapsulatedby the film. In particular, it is known that solvents in the compositionmay migrate into the film over time. This can cause a loss of integrityto the film by affecting its physical and mechanical properties. Forexample, the film and articles made therefrom, e.g., a pouch, sachet orbead, can become soft losing the ability to maintain their shape and/oreven their structural integrity. This migration of materials from thecomposition into the film may also cause the composition inside thearticle to become cloudy, viscous and/or exhibit poor dispersionproperties due to the loss of solvent. Likewise, solvents and/orplasticizers in the film can migrate into the composition encapsulatedby the film. This migration can also alter the encapsulated materialcausing it to become less desirable or effective in performing itsintended function.

To avoid issues relating to solvent migration, it is preferred that theprincipal solvent (or mixture of solvents) in the film compositioncomprise at least one common solvent that is present in the encapsulatedcomposition. For example, if the composition to be encapsulated is afabric enhancer product such as is described in WO 01/85892 Al, whichpreferably comprises 1,4-cyclohexanedimethanol, then preferably the filmcomposition should also comprise 1,4-cyclohexanedimethanol to mitigateagainst solvent migration and the deleterious effects that can resulttherefrom.

As noted above, the incorporation of a principal solvent in the filmforming composition can also improve the dissolution properties of afilm. It is well known that specific materials can render a filminsoluble delaying or preventing the disintegration and opening ofwater-soluble articles made from the film, and/or inhibiting thecomplete dissolution of the film material after the article has opened.There is particular concern that when the contents encapsulated in awater-soluble are released to the aqueous medium, those materials mayinhibit the complete dissolution of the remaining film material.However, it has been found that the use of at least one principalsolvent in the film material that is the same as one of the solventsused in the encapsulated composition will promote faster dissolution ofthe remaining film material. Compatibility between the film comprising aprincipal solvent and the encapsulated composition may be determined byusing the beaker test method that is described below.

Suitable solvents can also include low molecular weight alcohols,polyols, alcohol ethoxylates and the like. In addition, hydrotropes suchas sodium toluene sulfonate, sodium butyrate, sodium cumene sulfonate,sodium xylene sulfonate, and other hydrotropic materials can also beused to improve the cold water solubility of the film composition.

C. Adjunct Ingredients

The film-forming polymer may be further modified with various reagentscommonly employed in the film preparation art such as plasticizers,surfactants, anti-block agents, antifoamers, defoamers, biocides,perfumes, colorants, opacifiers, pearlescing agents, and the like.

To help provide flexibility to the film a plasticizer may be included inthe film-forming composition. The amount of plasticizer can range from0% to about 40%, by weight of the film-forming polymer. As shown in theexamples below, it is preferred that the film composition have betweenabout 2% to about 5% of a plasticizer. Suitable plasticizers includeglycerine, urea, poly(alkylene glycols) such as ethylene glycol,trimethylene glycol, tetramethylene glycol, pentamethylene glycol,hexamethylene glycol, propylene glycol, diethylene glycol, andtriethylene glycol, alkane diols such as 1,2 propanediol, 1,3propanediol, 2,3-butanediol, 1,4-butanediol, 1,3-butanediol,1,5-pentanediol, and 1,6 hexanediol; alkanolamines such astriethanolamine; alkanolamine acetates such as triethanolamine acetate;and alkanolacetamides such as ethanol acetamide. While glycerine ispreferred for most purposes, selection of an appropriate plasticizer ismade according to the ultimate required properties of the film. It isimportant to note that some materials have dual function serving both asa principal solvent and as plasticizer. Thus, several materials that areidentified above as principal solvents are also described herein assuitable plasticizers.

Representative of surfactants conventionally employed in the productionof water-soluble films include water-soluble anionic surfactants such ascarboxylate soaps, alkylarylsulfonates, alkanesulfonates,alpha-olefinsulfonates, fatty alcohol sulfates, and oxo-alcohol ethersulfates described in the technical literature including U.S. Pat. No.3,634,260 cited above and others. A preferred anionic surfactant classcomprises alkali metal salts of sulphated fatty alcohols containingabout 10 to about 18 carbon atoms, such as sodium lauryl sulfate andsodium stearyl sulfate. Suitable nonionic surfactants include thealkylphenol ethoxylates, fatty or oxo-alcohol polyethylene glycolethers, ethylene oxide-propylene oxide block copolymers, fatty alcoholpolygylcol ethers and ethoxylated fatty alcohols. To a lesser extentamphoteric or cationic surfactants may also be employed in thefilm-forming compositions of the invention, such as the alkyl betaines(sulfonated or nonsulfonated), quarternary ammonium salts and amineoxides. The surfactants may be used in amounts normally effective toassist in dispersion of water-soluble polymers, such as about 1% toabout 30% by weight of total film-forming composition.

Antifoam agents include the silicon polymers and defoamers includetallow compounds.

Useful biocides comprise any of the many known materials having efficacyagainst bacteria and other degrading organisms but which are non-toxicto handlers and to mammals or persons in the environment of use. Suchagents and the principles of selection are well known to those skilledin the art. Suitable biocides include quarternary ammonium salts such asalkyl(C8-C18) di(lower alkyl)benzylammonium chloride anddialkyldimethylammonium bromide.

Procedure For Making Polymer Films

A 250 ml beaker, stir bar and stirring hot plate can be used to make thepolymer films in the laboratory hood. First, the desired components areweighed out on a balance to obtain the desired percentage levels intothe beaker. Distilled water and a stir bar are added to the beaker. Thebeaker is placed on the hot plate to stir until all the components arecompletely dissolved. Finally, the solution is poured onto teflon platesto let the water evaporate off until the film is formed. Thisevaporation method usually takes about 1 to about 3 days. The dried filmpreferably has a thickness between about 20 microns and about 80microns.

Film-forming Composition Examples PVA** PVA** (M.W. 6,000, 80% (M.W.78,000, 88% Sample Film hydrolysis) hydrolysis) % CHDM 1 80% (˜2.0 g) 020% (˜0.5 g) 2 47% (˜1.3 g) 33% (˜0.9 g) 20% (˜0.5 g) *PVA = polyvinylalcohol starting material from Polysciences, Inc. **Dissolved in about100 ml of water. Film thickness is ˜75 microns

Film Examples PVA (M.W. 6,000, 1,6- Glycer- Film 80% hydrolysis) PVP POECHDM hexanediol ine 1 50% 30% 0 18% 0 2% 2 40% 0 40% 0 18% 2% PVP =polyvinyl pyrrolidone POE = polyethylene oxide CHDM =1,4-cyclohexanedimethanol

The film-forming compositions of the invention can be made into films ofvarying thickness on a commercial scale using conventional methods andtechniques such as solution casting and thermo-forming techniques. Filmsprepared from the film-forming compositions of the present invention arepreferably in the range of about 20 to about 100 microns in thickness,and more preferably between about 20 microns and about 80 microns.

In addition, the films of the present invention can be used effectivelyin the preparation of laminated or other multi-layered films. Forexample, an encapsulate formed from a two layer film can comprise of aninner layer made from a high molecular weight polyvinyl alcohol and/or alow degree of hydrolysis resin to provide a barrier layer in contactwith a material or composition that is encapsulated in the film. Asecond outer layer comprising a low molecular weight and/or high degreeof hydrolysis polyvinyl alcohol resin and a principal solvent may bedesirably to provide fast dissolution at the encapsulate's surface. Inaddition to compositional differences, the thickness of various layerswould likely differ; the inner layer having a thickness in the range ofabout 10 to about 40 microns and the outer layer having a thickness inthe range of about 30 to about 60 microns. Further, it may be desirableto provide a layer of material intermediate between film layers to aidin the handling and processing of multi-layer films.

In solution casting, the compositions are cast on a plate or belt usinga film applicator where they are allowed to dry. The films can then bevacuum-dried, followed by removal from the coating plate/belt. Castingtechniques are described in greater detail in U.S. Pat. No. 5,272,191issued Dec. 21, 1993 to Ibrahim, et al. which is incorporated herein byreference.

Films may also be prepared by a melt process, which typically involvesmixing the components together with sufficient water to allow thepolymer and principal solvent to melt at a temperature below theirdecomposition temperatures. The blended material is fed to an extruder,extruded under tension through an appropriate die, cooled with air andtaken up by an appropriate collection device. For making films, atubular film can be made with cool air being blown through the center ofthe tube to both cool the film and to impart a biaxial stress to thefilm. Extrusion processes can also be used to make other shaped articlesby using appropriate dies and molds. Examples of such thermo-formingprocesses are described in greater detail in U.S. Pat. No. 5,646,206issued Jul. 8, 1997 to Coffin, et al., said patent being incorporatedherein by reference.

Solubility Test Method

To determine the solubility of polymer films in cold water (40° F.) asimplified beaker test method was employed. More specifically, thebeaker test method was used to determine the amount of time it takes forthe film to break up into pieces (disintegration) and to dissolvecompletely (dissolution) by placing the film sample in a beakercontaining water at 40° F. with constant agitation.

The methodology consisted of cutting a sample of each film about 2 in.by 2 in. square and placing it in a 250 ml beaker containing about 100 gof cold water. A stirring bar was added and the beaker placed on aCorning® magnetic stir/hot plate, model number PC-420. The film andwater were stirred at a constant low speed (setting =3) until the pieceof film appeared to be completely dissolved visually. In determiningfilm solubility in a medium that does not allow visual inspection of thefilm (i.e. a fabric softening composition), the contents of the beakerwere poured through a strainer having openings of about 1 mm in diameterto catch any portions of the film that were not completely dissolved.When remnants of the film were caught in the strainer, the remnants weretransferred back to the beaker and the stirring continued until the filmcompletely dissolved. When the beaker contents pass through the strainerwithout leaving residue in the strainer, dissolution was complete. Thedissolution time required for the film to be able to pass through thestrainer without leaving residue was then recorded.

The following table provides film dissolution data concerning differentfilms with and without a principal solvent as well as data concerningthe interaction of the encapsulate composition with the film materialand the inhibitory effect on the dissolution of the film. For filmsdissolved in pure water and films dissolved in a fabric softeningcomposition, the dissolution times are dramatically shortened by theincorporation of a principal solvent into the film-forming composition.For films dissolved in pure water, the dissolution time of a film with aprincipal solvent were only about 25% to about 27% of the dissolutiontimes for films that did not comprise a principal solvent. Similarly,for films dissolved in a fabric softening composition, the dissolutiontime of a film with a principal solvent were about 40% of thedissolution time for films that did not comprise a principal solvent.

Film Dissolution Film Dissolution Film Dissolution Time in 40° F. Timein Fabric Hydrolysis 1,4-CHDM Water Softener* Film (%) MW (%) (min:sec)(min:sec) PVA 80 6,000 20 0:45 0:56 PVA 80 6,000 0 2:44 2:20 PVA 50/50mix of 50/50 mix 20 1:15 4:00 80% & 88% of 6,000 & 78,000 PVA 50/50 mixof 50/50 mix 0 5:00 10:00  80% & 88% of 6,000 & 78,000 *Downy Enhancer ®available from The Procter & Gamble CompanyArticles

Films made of the film-forming compositions of the present inventionhave a variety of useful applications. They are useful as coatings,adhesives, and in particular are useful in forming water-solublearticles such as pouches for dispensing pre-measured and/or hazardoussubstances. By way of example, pouches and their manufacture aredescribed in additional detail in U.S. Pat. No. 4,801,636, issued Jan.31, 1989 to Smith, et al. and U.S. Pat. No. 6,281,183, issued Aug. 28,2001 to Harbour, both of which are incorporated herein by reference.Controlled release matrices, carriers or coatings that are water-solublealso have numerous applications such as the application ofpharmaceutical preparations to the skin for transdermal delivery.Biodegradable materials that are carrier matrices such as tablets orencapsulation materials are also contemplated.

The range of materials that can be encapsulated and sealed within thefilms of the present invention is very broad and includes virtually anycomposition which is functional in a cold water environment or which maybe conveniently diluted in cold water before its intended use orapplication. The primary limitation is the water content of thecomposition. More specifically, it is difficult to encapsulatecompositions that have a high water content as such compositions tend tocause premature dissolution of the films.

Specific examples of compositions that are suitable for encapsulationwater-soluble film for subsequent dispersing in films include detergentsand other laundry compositions including fabric softening compositions.Non-limiting examples of fabric softening compositions that may beencapsulated are described in U.S. Pat. No. 5,861,370, which issued Jan.19, 1999 to Trinh, et al., U.S. Pat. No. 6,323,172 B2, which issued Nov.27, 2001 to Trinh, et al. and U.S. Pat. No. 6,335,315 B2 which issuedJan. 1, 2002 to Trinh, et al., all of said patents being incorporatedherein by reference. All manner of compositions that require dilution inan aqueous medium prior to use may be encapsulated in the films andarticles of the present invention.

Encapsulating a composition in a water-soluble film can be accomplishedusing conventional techniques and equipment. Encapsulation processesthat utilize vacuum forming are known in the art as described in U.S.Pat. No. 6,281,183 B2, issued Aug. 28, 2001 to Harbour, which isincorporated herein by reference. Equipment for performing suchencapsulation processes is commercially available for instance fromCloud Corporation, Des Plaines, Ill.

1. An article of manufacture comprising: a fabric softener to bereleased into an aqueous medium; a water-soluble film comprising afilm-forming composition, said water-soluble film encapsulating saidreleasable composition, wherein said water-soluble film compositioncomprises from about 50% to about 99.9% of at least one water-solublepolymer; and from about 0.1% to about 50% of at least one principalsolvent wherein the film forming composition, when formed into a filmcomprising a thickness of from about 20 microns to about 100 microns,will dissolve in a beaker of water at a temperature below about 68° F.in less than about 5 minutes with agitation and wherein the releasablecomposition and the film forming composition comprise a common principalsolvent.
 2. The article of claim 1, wherein the water-soluble polymercomprises a polyvinyl alcohol.
 3. The article of claim 1, wherein thefilm formed from the film-forming composition will dissolve in a beakerof water at a temperature below about 50° F. in less than about 2minutes with agitation.
 4. The article of claim 1, wherein thewater-soluble polymer comprises a mixture of two water-soluble polymershaving disparate molecular weights.
 5. The article of claim 4, whereinthe water-soluble polymer comprises a first polymer having a molecularweight greater than about 50,000.
 6. The article of claim 4, wherein theratio of high to low molecular weight polymers is greater than about50/50.
 7. The article of claim 2, wherein the polyvinyl alcohol is atleast partially hydrolyzed.
 8. The article of claim 7, wherein thepolyvinyl alcohol is less than about 90% hydrolyzed.
 9. The ice of claim7, wherein the polyvinyl alcohol is a mixture of at least two polyvinylalcohol materials, the two polyvinyl alcohol materials having differentlevels of hydrolysis.
 10. The article of claim 1, wherein the principalsolvent is an alcohol.
 11. The article of claim 1, additionallycontaining a surfactant.
 12. The article of claim 1, wherein theprincipal solvent is a diol.
 13. The article of claim 12, wherein theprincipal solvent is a cyclohexanedimethanol.
 14. The article of claim1, wherein the principal solvent has a C log P between from about −2 toabout 2.6.